BMW R850C Service Manual
Repair Manual
R 850 C
R 1200 C
BMW AG Motorcycle Division
After Sales
Published by: © BMW AG Motorcycle Division
After Sales
UX-VS-2
All rights reserved. Not to be reprinted, translated or duplicated either wholly or in part without prior written
permission.
Errors and omissions excepted; subject to technical amendment.
Printed in Germany 3/99
Order number 01 50 7 654 051
Introduction
This repair manual will help you to perform all the main maintenance and repair work correctly and efficiently. It should be consulted regularly by workshop personnel as an addition to the practical and theoretical
knowledge obtained in Training School courses. It is a contribution towards achieving even higher Service
quality.
A new issue of this repair manual will be published if amendments or additions (supplements) are needed.
The latest issue date is shown in the header of the microfiche. Microfiches rendered invalid by the new issue
should be destroyed without delay.
All information in both text and illustrations refers to motorcycles in standard condition or with Original BMW
accessories installed, and not to motorcycles which have been modified in any way to depart from the manufacturer’s specification.
● The repair manual is structured in the logical sequence of the work to be performed: Removal, Disman-
tling, Repair, Assembly, Installation.
● The entire contents are divided into individual chapters, corresponding to the Construction Groups.
11 . 10
Chap. Page number within chapter
● Work to be performed during an Inspection is described in Group 00. The various Inspection routines
are numbered I, II, III and IV. This numbering is repeated in the work descriptions which follow, so that
work can take place without interruption.
● Use of the BMW special tools needed for certain tasks is described in the work instructions.
If the need arises, repair instructions are also issued in the form of Service Information. This information is
of course incorporated into the next issue of the repair manual. We also recommend you to consult the
detailed illustrations on the Parts microfiches as an additional source of information.
BMW AG Motorcycle Division
After Sales
Published by: BMW AG Sparte Motorrad
Hufelandstr. 6
D - 80937 München
All rights reserved. Not to be reprinted, translated or duplicated either wholly or in part without prior written
permission.
Errors and omissions excepted; subject to technical amendment.
Produced in Germany
BMW AG Motorcycle Division
Maintenance schedule
R 1100 S / R 850/1200 C / R 1150 GS
Customer Licence plate No.
Order No. Mechanic’s signature
Read the fault code memory with the MoDiTeC
Change oil while at regular operating temperature and renew the oil filter element
if motorcycle is used only for short journeys or at outside temperatures under 0°C (32 °F), every
3 months, but at least every 3 000 km (1 800 miles)
)
*
BMW Inspection
at 1000 km
(600 miles)
BMW Service
every 10000 km
(6 000 miles)
BMW Inspection
every 20 000 km
(12000 miles)
BMW
Annual Service
Change oil in gearbox while at operating temperature
at least every 2 years*
)
Change oil in rear wheel drive while at regular operating temperature;
if necessary, clean inductive sensor on rear wheel
every 40 000 km (24 000 miles) or at least every 2 years *
Renew fuel filter *
normally every 40 000 km (24 000 miles), if fuel quality is poor every 20000 km (12 000 miles)
)
)
Check battery acid level, if necessary add distilled water
Clean and grease the battery terminals, if necessary
Renew intake air filter element
in very dusty or dirty operating conditions, renew the intake air filter element every 10000 km
(6 000 miles) or even more often if necessary
Renew Poly-V belt *
renew Poly-V belt every 60 000 km (36 000 miles); do not adjust
)
Check brake fluid level at front and rear and top up if necessary *
)
*
)
Check operation of brake system and freedom from leaks; repair/replace items if nec. *
Examine brake pads and discs for wear, renew if necessary *
)
Change the brake fluid annually
Check clutch fluid level
Change the clutch fluid
every 40 000 km (24 000 miles) or at least every 2 years *
)
Check tightness of rear wheel studs
Check rear wheel bearing play by tilting wheel
Check swinging arm bearings (zero play); adjust if necessary *
)
Grease the side stand pivot
Check function of side stand contact switch
Check condition of spark plugs
Renew spark plugs *
)
Check security of cylinder head nuts
Check/adjust valve clearances
Check throttle cable for free movement, abrasion and kinking; renew if necessary *
Check cable play
Check synchronisation and eliminate leaks *
)
Final inspection with road safety and functional check:
– Condition of tyres and wheels, rims and spokes if applicable, tyre pressures
– Lights and signalling equipment
– Telltale and warning lights
– Clutch, gear shift
– Front and rear brakes, steering
– Instruments
– If necessary, test ride
)
*
Charged as an additional item
every
2years
40 000
(24 000)
40 000
(24 000)
60 000
(36 000)
)
40 000
(24 000)
)
every
2years
every
2years
Order No. 01 71 0 008 872 UX-VS-2, 06.99 Printed in Germany
BMW AG Motorcycle Division
Pre-delivery check
R 1100 S / R 850/1200 C / R 1150 GS
Customer Licence plate No.
Order No. Mechanic’s signature
Check the shipping crate for damage
Motorcycle:
– unpack
– install remaining items
– inspect for damage
– check that delivery is complete: tools
documentation
keys
correct optional extras
Fill and charge the battery (mark with charging date)
Check engine oil level when cold; add oil if necessary
BMW
Pre-delivery check
Check clutch operating fluid level and brake fluid levels at front and rear
Check headlight beam angle, adjust if necessary
Check security of rear wheel studs
(comply with correct tightening torque)
Check tyre pressures
Fill fuel tank
Final inspection as functional check:
– Clutch, gear shift
– Front and rear brakes
– Lights and signalling equipment, telltale and warning lights, instruments
– Check operation of optional extras, ABS
– If necessary, test ride
Confirm pre-delivery check in Service and Technical Booklet
Final cleaning
Motorcycle handed over on:
Order No. 01 71 0 008 872 UX-VS-2, 06.99 Printed in Germany
Contents
Group / Chapter
00 Maintenance and general instructions
11 Motor
12 Engine electrics
13 Fuel preparation and control
16 Fuel tank and lines
18 Exhaust system
21 Clutch
23 Gearbox
31 Front fork
32 Steering
33 Rear wheel drive
Group / Chapter
34 Brakes
36 Wheels and tyres
46 Frame
51 Equipment
52 Seat
61 General electrical equipment
62 Instruments
63 Lights
00
00 Maintenance and general instructions
Contents Page
Tightening torques ......................................................................................................................3
Table of operating fluids ...........................................................................................................9
Key to maintenance intervals ..............................................................................................11
Reading out MoDiTeC fault memory ...............................................................................11
(Inspections I, II, III and IV)
Checking throttle cable play,
adjusting if necessary ..............................................................................................................11
(Inspections I and III)
Changing engine oil, renew oil filter element .............................................................12
(Inspections I, II, III and IV)
Changing oil in gearbox ..........................................................................................................13
(Inspections III and IV)
or at least every 2 years
Changing oil in rear wheel drive; cleaning inductive signal transmitter at
rear wheel .......................................................................................................................................13
(Inspections I, III and IV)
Every 40 000 km (24 000 miles) or at least every
2 years
Renewing fuel filter ...................................................................................................................14
(Inspection III)
In normal operating conditions every 40 000 km (24 000 miles); if fuel quality is poor every
20 000 km (12 000 miles)
Checking battery acid level/topping up if necessary, cleaning/greasing
battery posts .................................................................................................................................16
(Inspections III and IV)
Renewing intake air cleaner
element ............................................................................................................................................16
(Inspection III)
In very dirty and dusty operating conditions, renew every 10 000 km (6 000 miles) or even more frequently if necessary
Renewing Poly-V belt ...............................................................................................................17
(every 60 000 km/36 000 miles)
(Inspection III)
Poly-V belt adjusting procedure:
Checking brake fluid level .........................................................................................................18
Front brake
00.1
Contents Page
Rear brake
Checking brake pads and discs for wear/renewing ......................................................19
(Inspections II and III)
Checking front brake pad wear ..............................................................................................19
Checking rear brake pad wear ................................................................................................19
Checking brake disc wear ........................................................................................................19
Renewing brake pads Front brake ........................................................................................20
Renewing brake padsRear brake ..........................................................................................20
Renewing brake fluid and bleeding brake system ...................................................21
Renew the brake fluid annually
(Inspection IV)
[ABS Inspection II and III]
Bleeding front brake circuit/renewing brake fluid ...........................................................21
Additionally with [ABS]
Bleeding rear brake circuit/renewing brake fluid ............................................................23
Additionally with [ABS]
Checking clutch operating fluid level .............................................................................24
(Inspections I, II and III)
Checking tightness of rear wheel studs ........................................................................25
(Inspection I)
Checking rear wheel bearing play by tilting wheel .................................................25
(Inspection III)
Checking swinging arm bearings, adjusting if necessary ...................................25
(Inspections I and III)
Greasing the side (prop) stand pivot ................................................................................25
(Inspections I, II and III)
Checking function of side (prop) stand contact switch ........................................25
(Inspections I, II, III and IV)
Tightening cylinder heads .....................................................................................................26
(Inspection I)
Checking/adjusting valve operating clearances ......................................................26
(Inspections I, II and III)
Checking/renewing spark plugs ........................................................................................27
(Inspection II)/renewing (Inspection III)
Check synchronising ................................................................................................................27
(Inspections I, II and III)
Final inspection with road safety and functional check .......................................28
(Inspections I, II, III and IV)
Road safety check
Roadworthiness check
00.2
00
Tightening torques
Model R 850/1200 C
Connection Nm
11 Engine
Cylinder head
Tightening sequence:
1. Tighten cylinder head nuts (oiled) crosswise
1.1 Tighten all nuts to correct torque for joint 20
1.2 Tighten all nuts to correct angle 90°
1.3 Tighten all nuts to correct angle 90°
2. M 10 bolt 40
3. M 6 screw 9
After 1000 km (600 miles), tighten cylinder head nuts
crosswise:
1. Unfasten one nut
2. Tighten one nut to initial value 20
3. Tighten nut to wrench angle 180°
4. Unfasten/retighten M10 screw 40
Timing gear carrier to cylinder head
Bearing cap on rocker shaft 15
Locknut, valve adjusting screw 8
Cylinder head cover to cylinder head 9
Camshaft end cover to cylinder head
Air intake connection to cylinder head
Camshaft
Chain sprocket to camshaft 65
Camshaft bearing cap 15
Rotary breather
Vent line to alternator mount cover
M 8 screw 20
Banjo screw 25
Alternator mount cover
M 6 screw 9
9
9
9
M 8 screw 20
Auxiliary shaft
Chain sprocket to crankshaft 10
Chainwheel to auxiliary shaft 70
Chain tensioner housing to engine block 9
00.3
Model R 850/1200 C
Connection Nm
11 Engine
Oil filter
Oil filter 11
Oil drain plug 32
Oil pump
Mesh filter basket to engine block 9
Oil pump cover 9
Pressure relief valve 35
Oil pressure switch 30
Oil cooler
Oil cooler pipe to engine block 10
Cooling oil line - banjo screw with oil vent valve 25
Oil cooler to frame 9
Oil cooler return line to engine block 35
Screw-in union for oil cooler connection at engine
block
35 (clean threads and apply Loctite 603 to inner
and outer threads and in the contact face area)
Cylinders
Tightening sequence:
1. M 8 screw 20
2. M 6 screw 9
3. Chain guide rail pivot screw 18
Timing chain
Chain tensioner 32
Connecting rod
Big end cap Joint torque 20
Additional wrench
angle 80°
Crankcase
Tightening sequence:
1. M10 screw (oiled) 45
2. M 8 screw (oiled) 20
3. M 6 screw 9
00.4
Model R 850/1200 C
Connection Nm
12 Engine electrics
Starter motor to engine 20
Starter cover to housing 7
Positive lead to starter motor 10
Alternator to cover mount 20
Tensioning and retaining strap at alternator 20
Spacer at alternator 20
Positive lead to alternator 15
Belt pulley at alternator 50
Belt pulley to crankshaft 50
Poly-V belt preload 8
Spark plug 20
Ignition coil holder to frame 9
13 Fuel preparation and control
Oil temperature sensor to engine block 25
Air temperature sensor to air cleaner cover 10
16 Fuel tank and lines
Fuel tank to rear frame 10
18 Exhaust system
Manifold to cylinder head 24
Clip on muffler 55 (apply Never Seez to clip contact surface)
Oxygen sensor (lambda probe) to muffler 45 (apply Never Seez to thread)
21 Clutch
Clutch housing Joint torque
Additional wrench
angle 32°
Housing cover 12
Slave cylinder to gearbox 9
40 (oil screw threads lightly)
Clutch line to handlebar fitting 18
00.5
Model R 850/1200 C
Connection Nm
23 Transmission
Oil filler plug 23
Oil drain plug 55
Gearbox to engine block 22
Gear shift pedal to rear frame 41
Selector lever to selector shaft 9
Gearbox cover to gearbox housing 9
31 Front fork
Fixed tube to fork bridge 35 (free from oil and grease)
Slider tube bridge to slider tube 22 (clean thread + Loctite 243)
Quick-release axle clamp screws 20
Threaded journal to frame 130 (clean thread + Loctite 243)
Ball joint to fork slider bridge 230 (apply light coat of Never Seez to thread)
Leading link to ball joint 130 (clean thread + Loctite 2701)
Leading link to engine right 73
Screw cap at leading link left 42 (apply light coat of Never Seez to thread)
Spring strut to frame
Spring strut to leading link
32 Steering
Handlebar at fork bridge 21 (apply light coat of Never Seez to thread)
Twistgrip to handlebar 8
33 Rear wheel drive
Oil filler plug 23
Oil drain plug 23
Threaded ring 118 (Hylomar SQ 32 M)
Hexagon nut, input bevel gear
Cover at rear-wheel drive housing 35
Rear-wheel drive to swinging arm 24
40
40
200 (clean thread + Loctite 2701)
Swinging arm bearing journal to rear frame right 9
Swinging arm bearing journal to rear frame left 7 (clean thread + Loctite 2701)
Locknut at swinging arm bearing journal 160
Suspension strut to rear frame 50
Suspension strut to rear swinging arm 50
00.6
Model R 850/1200 C
Connection Nm
34 Brakes
Brake caliper at fork slider tube 40
Brake caliper to rear wheel drive 40
Brake disc to front wheel 24 (clean thread + Loctite 2701)
34 Brakes
Brake disc to rear wheel drive 21 (clean thread + Loctite 2701)
Master cylinder to footrest assembly 8
Brake pedal to footrest assembly 37
Brake lines/brake hose to brake
components 18
ABS sensor 4 (handtight)
Front brake caliper bleed screw
Rear brake caliper bleed screw
Pressure modulator bleed screw
36 Wheels and tyres
Quick-release axle clamp screws 20
Quick-release axle threaded connection 30
Rear wheel to rear wheel drive
Screw wheel studs in handtight, then tighten
in a crosswise pattern
Initial tightening 50
Final tightening 105
7
4
9
00.7
Model R 850/1200 C
Connection Nm
46 Frame
Frame to engine
M12 pin 82
M10 screw 58
Rear frame
to engine 41
to gearbox 71
Side (prop) stand pivot mount to engine 21
Side (prop) stand to pivot mount
Footrest assembly to engine
M12 screw 71
M8 screw 21
Pillion footrest holder to rear frame 21
Pillion seat mount 21
Mudguard to slider tube bridge 8
51 Equipment
Mirrors 15
Ignition/steering lock to fork bridge 15 (shear bolt)
61 General electrical equipment
Horn to holder 13
Ground (earth) strap to engine block 10
63 Lights
42 (clean thread + Loctite 243)
Headlight to holder 15
00.8
Table of operating fluids
Item Use Order number Quantity
Lubricant
Optimoly MP 3 High-performance lubricating paste 07 55 9 062 476 100 g tube
Optimoly TA High-temperature assembly paste 18 21 9 062 599 100 g tube
Silicone grease 300, heavy Damping grease 07 58 9 058 193 10 g tube
Retinax EP2
Contact spray Contact spray 81 22 9 400 208 300 ml aerosol
Chain spray Drive chain
Sealants
3-Bond 1110 B Surface sealant 07 58 9 056 998 5 g tube
3-Bond 1209 Surface sealant 07 58 9 062 376 30 g tube
omni VISC 1002 Surface sealant 07 58 1 465 170 90 g tube
Loctite 574 Surface sealant 81 22 9 407 301 50 ml tube
Curil K 2 Heat-conductive sealant 81 22 9 400 243 250 g can
Hylomar SQ 32 M Permanently elastic sealant 81 22 9 400 339 100 g tube
Adhesives and retaining
agents
Loctite 648 Joint adhesive (low clearance) 07 58 9 067 732 5 g bottle
Loctite 638 Joint adhesive (greater clearance) 07 58 9 056 030 10 ml bottle
Loctite 243 Thread retainer, medium-strength 07 58 9 056 031 10 ml bottle
Wheel, steering head and taper roller
bearing grease
83 22 9 407 845 100 g tube
72 60 2 316 676
72 60 2 316 667
50 ml spray
300 ml spray
Loctite 270 Thread retainer, strong 81 22 9 400 086 10 ml bottle
Loctite 2701 Thread retainer, strong 33 17 2 331 095 10 ml bottle
Loctite 454 Cyanacrylate adhesive (gel) 07 58 9 062 157 20 g tube
Cleaner
Brake cleaner Brake cleaner 83 11 9 407 848 600 ml aerosol
Metal Polish Polish for chromium plated parts 82 14 9 400 890 100 g tube
Testing agent
Penetrant MR 68
Entwickler MR 70
Crack testing agent for aluminum
housings
Crack testing agent for aluminum
housings
83 19 9 407 855 500 ml spray
81 22 9 407 495 500 ml spray
00.9
00.10
Key to maintenance intervals
– BMW Inspection
1000 km/600 miles I
– BMW Service II
– BMW Inspection III
– BMW Annual Service IV
Reading out MoDiTeC fault memory
(Inspections I, II, III and IV)
Remove the left air cleaner trim panel.
•
Connect MoDiTeC to diagnostic plug.
•
Read out the fault memory.
•
Perform any repair work indicated.
•
Checking throttle cable play,
adjusting if necessary
(Inspections I and III)
Check throttle cable for free movement and free-
•
dom from abrasion or kinking; renew if necessary.
With the steering turned to various angles, open
•
the throttle twistgrip fully and allow it to close
again.
When released, the twistgrip must return to the
•
closed position by itself.
C000010
Pull back the protective cap.
•
Preset throttle cable play with the engine cold to
•
1.5 mm (0.06 in).
Warm the engine up to its regular operating tem-
•
perature.
Adjust throttle cable play to 0.5 mm (0.02 in).
•
Adjusting value:
Initial throttle cable play setting
(engine cold) ................................. 1.5 mm (0.06 in)
Throttle cable play (engine warm).. 0.5 mm (0.02 in)
00.11
Changing engine oil, renew oil filter
element
(Inspections I, II, III and IV)
L Note:
If the motorcycle is ridden only for short distances or
outside temperatures are below 0°C (32°F): change
the oil and renew the oil filter element every
3 months, but at least every 3 000 km (1 800 miles).
Change the oil while it is at regular operating
•
temperature.
Unscrew oil drain plug and drain off oil.
•
Fit new seal and screw in drain plug.
•
11 4 650
C000030
Use oil filter wrench, BMW No. 11 4 650, to un-
•
screw and remove the oil filter.
Coat sealing ring on new oil filter element with oil
•
and screw in.
Add oil.
•
Insert and tighten the screw plug.
•
Check engine oil level with the motorcycle in a
•
horizontal position; use the auxiliary stand,
BMW No. 00 1 550.
Remove screw plug.
•
C000240
e Caution:
Never add engine oil above the MAX mark.
X Tightening torque:
Oil filter......................................................... 11 Nm
Oil drain plug................................................ 32 Nm
Fill quantity for engine:
With oil
filter change ..3.75 l (6.6 Imp. pints/3.96 US quarts)
Without oil
filter change ..3.50 l (6.2 Imp. pints/3.69 US quarts)
Oil volume between MIN and
MAX marks......0.50 l (0.88 Imp. pint/0.52 US quart)
Engine oil grade:
Brand-name HD oil for four-stroke spark-ignition engine, API classifications SE, SF, SG; combination
with CC or CD specification.
00.12
Changing oil in gearbox
(Inspections III and IV)
or at least every 2 years
Change the gearbox oil while at regular operating
•
temperature.
Changing oil in rear wheel drive;
cleaning inductive signal transmitter
at rear wheel
(Inspections I, III and IV)
Every 40 000 km (24 000 miles) or at least every
2 years
Change the gearbox oil while at regular operating
•
temperature.
2
3
1
C000040
Loosen clip/trim (1) at right silencer and turn
•
downwards.
Take out oil filler plug (3) and oil drain plug (2) and
•
allow the oil to drain out.
Clean the magnet in the oil drain plug.
•
Insert the oil drain plug again.
•
L Note:
Add oil to the gearbox up to the lower edge of the
filler hole, then place the motorcycle on its side
(prop) stand and add the remaining 0.2 litre
(0.35 Imp. pint, 0.21 US quart).
Add gearbox oil.
•
Insert oil filler plug with new seal.
•
X Tightening torque:
Oil drain plug................................................ 55 Nm
Oil filler plug ................................................. 23 Nm
Exhaust pipe clip at silencer (muffler) ........... 55 Nm
5
6
4
C000050
e Caution:
Note that the interior of the gearbox is slightly pressurised.
Slacken off oil drain plug (4) so that the pressure
•
drops.
Unscrew and remove oil filler plug (5).
•
Unscrew and remove oil drain plug (4) and allow
•
the oil to drain out.
Fit new seal and screw in drain plug.
•
Add gearbox oil.
•
Insert oil filler plug with new seal.
•
Release the fastening, pull out inductive signal
•
transmitter (6) and clean it.
X Tightening torque:
Oil drain plug................................................ 23 Nm
Oil filler plug ................................................. 23 Nm
Fill quantity:
Initial filling.......1.0 l (1.76 Imp. pints/1.06 US quart)
During
oil changes......1.0 l (1.76 Imp. pints/1.06 US quart)
Oil grade for gearbox:
Brand-name hypoid gear oil, SAE 90, API class GL 5
Fill quantity:
Initial filling up to lower edge of filler
hole.........app. 0.20 l (0.35 Imp. pint/0.21 US quart)
Oil change up to lower edge of filler
hole.........app. 0.20 l (0.35 Imp. pint/0.21 US quart)
Oil grade for rear wheel drive:
Brand-name hypoid gear oil, SAE 90, API class GL 5
00.13
13 3 010
Renewing fuel filter
(Inspection III)
In normal operating conditions every 40 000 km
(24 000 miles); if fuel quality is poor every
20 000 km (12 000 miles)
Remove seat.
•
Remove right air cleaner trim panel.
•
Remove left and right trim panels.
•
e Caution:
Fuel is flammable and a hazard to health. Observe
relevant safety regulations.
Take off the fuel tank.
•
Seal the fuel feed and return lines with a hose
•
clip, BMW No. 13 3 010, detach and pull off.
C160010
Pull the plug connector off the fuel pump assem-
•
bly.
Lift off fuel tank.
•
00.14
Drain fuel tank.
•
Remove fuel pump assembly.
•
Detach hoses from fuel filter (1).
•
2
1
C160020
X Tightening torque:
Fuel pump unit .............................................. 5 Nm
e Caution:
Note correct direction of flow through fuel filter.
Use only an O-ring seal (2) in good condition.
After installing, check fuel pump assembly for leaks.
Fit new fuel filter.
•
Secure non-reusable hose clips with pliers,
•
BMW No. 13 1 500.
Installing:
L Note:
Note correct path of vent lines.
00.15
C000020
Checking battery acid level/topping
up if necessary, cleaning/greasing
battery posts
(Inspections III and IV)
Release the rubber strap holding the battery.
•
Raise the battery and check its acid level.
•
Top up battery acid level with distilled water as
•
far as the MAX mark.
Protective
battery-post grease: ...............e.g. Bosch Ft 40 V1
Renewing intake air cleaner
element
(Inspection III)
In very dirty and dusty operating conditions,
renew every 10 000 km (6 000 miles) or even
more frequently if necessary
Detach and raise the upper part of the air cleaner
•
housing.
Renew air cleaner element.
•
Install the fuel tank.
•
Note correct path of vent lines.
•
Install the left/right trim panels.
•
X Tightening torque:
Fuel tank to rear frame ................................. 10 Nm
00.16
Renewing Poly-V belt
(every 60 000 km/36 000 miles)
(Inspection III)
3
12 3 510
C000060
Remove the cover.
•
Use the spark plug cap assembly tool from the
•
toolkit to pull off the spark plug caps.
Use spark plug wrench, BMWNo.123510, to
•
unscrew and remove the spark plugs.
TDC
4
2
1
RS110480
Slacken off alternator mounting screws (1,3,4)
•
and install a new Poly-V belt if necessary.
Poly-V belt adjusting procedure:
Poly-V belt installation procedure:
Place the Poly-V belt in position, tension it and
•
turn the engine over once, then release belt tension.
Poly-V belt tensioning procedure:
1. Screw hex nut (1) on adjusting screw (2) up
handtight (no tools to be used)
2. Tighten adjusting screw (2) with a torque wrench
and keep it under tension.
3. Tighten upper retaining nut (3), then release the
tension at the adjusting screw.
4. Tighten all screws and nuts.
X Tightening torque:
Poly-V belt preload......................................... 8 Nm
Alternator to alternator support cover........... 20 Nm
Vent line at generator mount cover:
Banjo screw................................................. 25 Nm
Machine screw............................................. 10 Nm
1
Remove the horn with its mount.
•
Remove front cover.
•
Remove vent line (1).
•
C000070
e Caution:
Install the vent line with new O-ring seals.
00.17
Checking brake system for correct
operation and freedom from leaks;
repairing/renewing if necessary
(Inspection III)
Checking brake system for leaks.
•
Checking brake fluid level
L Note:
The brake fluid volume (between MIN and MAX) is
sufficient for the complete range of pad wear from
new to the wear limit.
It is not normally necessary to add fluid to compensate for pad wear.
If the level drops below the minimum mark, this indicates some other fault.
Rear brake
Position the motorcycle horizontally with auxiliary
•
stand, BMW No. 00 1 550.
Brake fluid must not drop below the minimum
•
level (arrow).
(Inspections I, II and III)
Front brake
Make sure that the specified setting (distance
•
between handlebar and fuel tank 30-50 mm/
1.2-2 in) is correct.
Check with the motorcycle on its side (prop)
•
stand.
Turn the handlebar fully to the left.
•
The brake fluid must not drop below the mini-
•
mum level 2 mm (0.08 in) below the ring mark (arrow).
C000090
Brake fluid grade .........................................DOT 4
CUB0110
Brake fluid grade.........................................DOT 4
00.18
Checking brake pads and discs for
wear/renewing
(Inspections II and III)
Checking front brake pad wear
C000100
Checking rear brake pad wear
C000120
It should not be possible to see the brake disc
through the hole (arrow) in the inner brake pad.
If the brake disc is visible, the wear limit has been
reached and the pads must be renewed.
Checking brake disc wear
C000110
Examine the wear limit marks (arrows).
•
e Caution:
Brake pad thickness must not fall below the minimum
value.
Change pads only as a complete set.
Minimum lining thickness: .......... 1.5 mm (0.06 in)
C000130
Examine the brake discs carefully for cracks,
•
damage, distortion, wear and score-marks.
Brake disc wear limit:
front:........................................... 4.5 mm (0.177 in)
rear:............................................ 4.6 mm (0.181 in)
00.19
Renewing brake pads
Front brake
Renewing brake pads
Rear brake
C000100
Detach/remove brake caliper from mounting (ar-
•
row).
1
2
C000230
Remove the split-pin keeper (1) from the retain-
•
ing pin (2).
Drive out retaining pin (2).
•
Remove brake pads by pulling downwards.
•
Install by following the above work instructions in
•
the reverse order.
Before installing the brake caliper, force the pis-
•
tons fully back with resetting tool,
BMW No. 34 1 500.
C000140
Loosen the rear wheel.
•
Unfasten/remove brake caliper.
•
Remove circlip (arrow) at retaining pin.
•
Drive the retaining pin out towards the wheel
•
side.
Remove brake pads.
•
Install by following the above work instructions in
•
the reverse order.
Before installing the brake caliper, depress the
•
piston fully.
X Tightening torque:
Brake caliper to rear wheel drive.................. 40 Nm
Screw the rear wheel studs in handtight, then
tighten them in a crosswise pattern.
Initial tightening............................................ 50 Nm
Final tightening........................................... 105 Nm
X Tightening torque:
Brake caliper at fork slider tube.................... 40 Nm
00.20
Renewing brake fluid and bleeding
brake system
Renew the brake fluid annually
(Inspection IV)
[ABS Inspection II and III]
Bleeding front brake circuit/renewing
brake fluid
L Note:
This description applies to brake filling and bleeding
devices with vacuum extraction of the brake fluid at
the brake caliper.
If other devices are used, comply with their manufacturers’ instructions.
Turn the steering to the left.
•
e Caution:
When bleeding the brakes, always start on the right
side.
Take off the brake caliper.
•
Remove the brake pads.
•
Take off reservoir cover with rubber diaphragm.
•
Release the right handlebar switch.
•
Loosen the clamp screw for the handbrake fitting
•
and turn the fitting until the brake fluid reservoir
is horizontal.
KR340280
e Caution:
When adding brake fluid, do not allow it to enter the
holes for the reservoir lid screws.
Add brake fluid up to the MAX mark (arrow).
•
Connect the brake bleeding device to the bleed
•
screw on the right brake caliper.
Open the bleed screw by half a turn.
•
Draw off brake fluid until it emerges clear and
•
free from air bubbles.
Close the bleed screw on the right brake caliper.
•
Repeat the bleeding process at the left brake
•
caliper.
34 1 500
C000150
Force the pistons fully back with resetting tool,
•
BMW No. 34 1 500.
e Caution:
Do not allow brake fluid to come into contact with
painted parts of the motorcycle, because brake fluid
destroys paint.
When installing:
L Note:
Clean the rim of the reservoir, the rubber gaiter and
the cover to remove brake fluid, and re-assemble
the components with great care.
e Next check brake fluid level with the motorcy-
cle on its side (prop) stand and the handlebar turned
to the left, and ensure that no air bubbles are visible
in the sight glass.
00.21
Additionally with [ABS]
C000160
Connect the brake bleeding device to the pres-
•
sure modulator for the front brake (arrow); this is
marked VR.
Open the bleed screw by half a turn.
•
Draw off brake fluid until it emerges clear and
•
free from air bubbles.
Close the bleed screw.
•
Bleed the left brake caliper in precisely the same
•
way as on the right.
If necessary, repeat the brake bleeding proce-
•
dure at the right/left.
X Tightening torque:
Bleed screw on pressure modulator...............9 Nm
34 1 520
Take out the resetting tool and insert spacer,
•
BMW No. 34 1 520, in its place.
Press the pistons back in the second brake cali-
•
per, but do not remove the resetting tool.
Fill and bleed the front brake circuit.
•
Installation takes place in the reverse order of re-
•
moval.
Brake fluid grade .........................................DOT 4
C000170
X Tightening torque:
Brake caliper to fork tube............................. 40 Nm
Bleed screw at brake caliper.......................... 7 Nm
00.22
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